Construction of Telecom TowersQuality and Productivity Improvement

Final Presentation
BTP Guide: Prof. K N Satyanarayana Dept. of Civil Engineering Presented By: N S B Syam CE05B038

Introduction
In the next three to four years, telecom companies (Telco's) will need another 100,000 towers and the industry estimates that at least 60 per cent of this will be built by independent operators.
The development of the Infrastructure segment in our country is associated with many issues like poor quality, lack of safety concerns, cost overruns and project delays due to inefficient project planning and control.
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 Prominent telecom infrastructure companies Reliance Communications, Bharti/Airtel, Vodafone, Idea Cellular, Aircel Ltd, MTNL, BSNL, VSNL etc.
Independent telecom infrastructure companies -Tata, ATC (American Tower Corp), Indus Towers, Quippo Telecom and GTL Infra Ltd.

Objectives
Basic study on contracting procedures, quality, cost, time, and productivity issues in telecom tower construction industry. Suggesting productivity improvement methods using logistics in terms of supply chain management and process mapping of the whole construction process. Identifying the underlying issues and suggestions for quality in the construction of communication towers.

Scope
The study is limited only to address the construction related issues. Design related issues are not in the scope of the study.
The study is limited to construction of telecom towers in and around Chennai. The study is focused on contracting procedures, quality problems, cost overruns, project delays in the construction of telecom towers and developing a logistics model in terms of supply chain management.
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Methodology
Discussions with experts in telecom towers construction industry. Interviews of client representatives, contractor representatives and site supervisors. Study and analysis of data collected from the on-going projects. Developing a Logistics model to map the construction process in terms of the supply chain management.
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 Study required extensive site visits, to collect data from the concerned personnel and to identify the key issues prevalent in the construction of telecom towers. Fifteen sites were visited as a part of this project. Three main types of issues identified: Quality of the construction process Schedule of the construction process. Productivity of the construction process

Quality Issues
Broadly classified into 7 categories based on site data and interviews conducted
Material/Equipment Availability Formwork/Reinforcement Geotechnical Issues Issues related to Concrete Structural Issues Labor Issues Site Management Issues
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Issues Vs. No. of sites

Issues
Material/Equipment Availability Formwork/Reinforcement Geotechnical Issues Concrete related Issues RTT (Total:8) 2 7 8 GBT (Total:7) 3 7 4 7

Structural Issues
Labor Issues Site Management Issues

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8 5

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7 7

Material/Equipment Availability
Aggregates, Sand, Cement
Steel for reinforcement Labor Pump for water pumping Vibrator for concrete Pulleys and bolts for tower erection Rubber soling to prevent seepage of water from underneath the foundation

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Formwork/Reinforcement

Quality of shuttering material Irregularity of Foundation bolts Leveling of formwork Inadequate development lengths for column extension
Required Ld is 200mm but available length was 75mm.

Congested Reinforcement Early removal of formwork

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Geotechnical Issues
Soil Investigations
IS 6403- Code of Practice for determining Bearing Capacity of Shallow Foundation Sufficient number of undisturbed samples of 40-100mm are required for testing Budget for soil test on a 6mx12m site is Rs.8000

Lack of laboratory in vicinity

Achieving required depth for foundation

IS 1080-1985- Code of Practice foe Design and Construction of Shallow Foundation in Soils Min. required foundation depth is 3m

Validity of the soil test report when compared to the actual conditions
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Concrete
Proper mix design
IS 10262: Code of Practice for Concrete Mix Design

Concrete cover for bolts/members

Min. cover in Chennai not less than 45mm

Improper Maintenance/Finishing
Segregation & Honeycombing
Honeycombing noticed in all the sites visited

Lack of proper cube testing for checking concrete strength

IS 4031-1968 28 day compressive strength( Appendix C, Clause 3.8) M20 Grade IS 9013-1978 Accelerated curing method for determination of compressive strength
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Structural Inadequacies Constructability issues

Missing Bracings/Fasteners
IS 204 (Part 1) :1991- Tower Bolts Specifications

Movement of foundation

Ad hock site modifications Template Setting

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Labor
Poor skill of labor Safety rules not followed at sites
SP 70:2001 Handbook on Construction Safety Practices

Lack of coordination among labor

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Site Management Issues

Supervision at sites Drawings/reports of tests
Poor Handling & Storage of materials Accessing the site
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Scheduling Issues
Labor
Unavailability of supervisors Timely availability of material/equipment Weather Holidays

No written work schedule

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Average Schedule of a 15m RTT-34 days duration

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Slowest Completed Schedule of a 15m RTT-56 days duration

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Fastest Completed Schedule of a 15m RTT-22 days duration

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Analysis of RTT schedules

30 days difference between slowest and fastest completed towers
Delay of 18-21 days due to material availability Delay of 3-4 days due to the delay between the installation of the tower equipment after the tower framework is erected Delay of 2-3 days is caused due to the prolonged installation period of the telecom equipment Delay of 2-3 days is caused in between the tower installation and the tower being on air
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Average Schedule of a 30m GBT-47 days duration

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Slowest Completed Schedule of a 30m GBT-65 days duration

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Fastest Completed Schedule of a 30m GBT-34 days duration

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Analysis of GBT schedules

Difference of 31 days between the fastest and the slowest completed towers
Delay of 19-21 days caused due to supply of construction material, tower material and the telecom equipment Delay of 2-3 days between each of the foundation levels Delay of 5-7 days between the installation of the tower and the completion of the tower foundation

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Process Mapping
1. What is Process Mapping? 2. Why are we applying Process Mapping?
3. How is it useful in this project?

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Process Mapping is a powerful tool that offers an in-depth understanding of any given process, finds effective ways for that process to be more successful, and ensures that true value is being provided to the client/customer.
There are four major steps of Process Mapping
Process identification attaining a full understanding of all the steps of a process. Information gathering identifying objectives, risks and key controls in a process. Interviewing and mapping understanding the point of view of individuals in the process and designing actual maps. Analysis utilizing tools and approaches to make the process run more effectively and efficiently.

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 Process Mapping is used in this project to identify the different processes that constitute the telecom tower construction.

Helps in increasing the productivity of the overall process by focusing on the processes that need rework for their improvement.
Telecom tower construction consists of a lot of processes ranging from Radio Frequency survey to the handing over of the completed tower on air. It allows all the individuals working on the project to gain a better understanding of that process with a simple, yet powerful approach that anyone can utilize.

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Process Identification Worksheet

Area of business being reviewed: Telecom tower construction Trigger Events Process Name Growth of mobile phone users in the country. Need for better networking and RF Survey hence construction of telecom towers. Survey done to locate the right locations for the tower constructions. Optimal location of tower site for better reach of customers. Site Identification/ Land Acquisition Drawings for the construction of towers. Layout Plans Type of foundation needed for GBTs for the construction. The structural Soil Investigation/ stability of the existing structure for RTTs. Structural Stability Protection and to prevent trespassing and misuse of the tower, fencing and Fencing, Compound wall, guard room to be constructed. Safety and protection of tower. Guard Room, DG Slab, Shelter Foundation Construction materials like, steel, sand, cement, aggregates for the tower Tower Supply & Erection foundation construction, tower fabrication set for tower material and equipment like vibrator, pulleys for tower erection. Diesel Generator set installation which is the key component of the tower DG set installation construction. Shelter for the security guard and to store maintenance parts for emergency Shelter Supply & Erection replacement of parts of the tower. Earthing to prevent damage by lighting and electrical works in order to ensure Electrical- Indoor, Outdoor proper functioning of the antennae. and Earthing Backup power options for the transmission of signals. AC installation, Battery, PIU Need for a base station to receive and transmit signals. Installation of BTS Need for the transmission of signals. Antennae Installation Connections of antennae to the electrical systems for proper functioning of the RF Cable Routing system. 40

Comprehensive Business Time Line Worksheet

Telecom Tower Construction Site Identification/Land Site Identification/Land Acquisition Acquisition Tender 2- Company D

Surveying Surveying

RF Survey RF Survey Tender 1Company C

Civil Works Civil Works

Layout Plans Layout Plans

Soil Investigation/Structural Stability Soil Investigation/Structural Stability Analysis Analysis

Fencing/Compound Wall, DG Slab, Shelter Fencing/Compound Wall, DG Slab, Shelter Foundation Foundation

Tower Foundation

Tender 3 Company A

Electrical & Mechanical Electrical & Mechanical Works Works

Tower Supply & Tower Supply & Erection Erection

Shelter Supply & Shelter Supply & Erection Erection

Electrical- Indoor, Outdoor and Electrical- Indoor, Outdoor and Earthing Earthing

Tender 3 Company A

Telecom Works Telecom Works

AC Installation, AC Installation, Battery, PIU Battery, PIU

Installation of Installation of BTS BTS

Antennae Antennae Installation Installation

RF Cable RF Cable Routing Routing

Wi-max Wi-max Installation Installation

Tender 4 OEMs Company B

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Process Name and Number RF survey : 1 Description :

Process Owner Principal Companies/Telecom Companies

The ultimate goal of a RF site survey is to supply enough information to determine the number and placement of access points that provides adequate coverage throughout the facility. In most implementations, "adequate coverage" means support of a minimum data rate. A RF site survey also detects the presence of interference coming from other sources that could degrade the performance of the wireless LAN. Triggers

Process Profile Worksheet

Event Beginning: Call for tenders for RF surveying. Event Ending Process: Document findings of the sites best suitable for telecom tower construction. Additional Events: Call for tenders for more than 1 company to save time. For 100 sites to be RF surveyed, 10 companies could finish the survey in 10 times less time than the survey being done by a single company. Inputs Items and Sources Surveying equipment like Theodolite, GPS, Satellites Outputs Items and Sources Optimal location of sites for the construction of telecom towers Process Units Obtain a site facility diagram Visually inspect the site facility Identify cellular phone user areas Determine preliminary site access point locations Verify site access point Business Objectives Location of sites which offer better transmission of signals and networking Key Controls Skilled usage of GPS systems and accuracy of the instruments. Business Risks Time consuming and tiring process. A slight change in the site location may not yield transmission signals. Accuracy is very important. Measure of Success Best fit site which can ideally transmit and receive 42 signals with maximum efficiency. Process Unit Owners Telecommunication Companies

Tower Construction Initiation

Site Identification/ Land Acquisition

Type of Tower

RTT

Structural Stability Analysis

GBT RF survey Negotiations with the owner Soil Investigation

No

Obtain an area facility diagram Successful Negotiation Tower and Shelter Material Supply

Visually inspect the facility area

Common Civil works

Yes Land acquired for tower construction

Identify cellular phone user areas

Guard Room foundation

Formwork and Reinforcement

Layout Plans Determine preliminary access point locations Fencing

Concreting

Verify access points

Superstructure of the guard room

Tower and Shelter Erection

DG set

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Telecom Installations

Electrical

Antennae Installation

GSM Indoor Outdoor

Microwave

Installation of RBS

Routing of cables

Installation of PIU, power backup

Site on air Fixing of cable ladder Clamping

Installation of rectifier and battery bank

Ground/ Earthing

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Suggestions
Prior stacking of materials at the job site Adequate supervision More labor compared to peak labor requirement Use of process charts and work schedules Safety equipment Use of vibrator and other equipment to prevent segregation and honeycombing Use of system formwork Grouting of bolts Leveling of beams, columns and template settings Centralized warehouse catering the needs of each construction site
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References
Dileep R. S, 2001, Logistics of Facility Location and Allocation, United States of America, Marcel Dekker, Inc. Jacka, M J., 2002, Business Process Mapping, United States of America, John Wiley & Sons, Inc. LakshmiNag P (2006), Productivity Issues in Construction of Steel Communication Towers, Bachelor of Technology Thesis, Indian Institute of Technology Madras, Chennai Kumar S, 2006-Types and Design of Steel Towers, Structural Steel Design, Indian Institute of Technology, Madras, http://nptel.iitm.ac.in/courses/IIT-MADRAS/Design_Steel_Structures_II, (accessed May 2006)

IS 204 Part 2 :1992 Tower Bolts Specifications

IS 456 (2000) Plain and Reinforced Concrete-Code of Practice IS 800 (2007) - General Construction in SteelCode of Practice IS 802 (Part 1/Sec 2): 1992 Use of Structural Steel in Overhead Transmission Line Towers- Code of Practice IS 806: 1988 - Code of Practice for use of Steel Tubes in General Building Construction IS 10262 Recommended Guidelines for Concrete Mix Design IS 875 Part 3: 1987 Code of Practice for Design Loads for Buildings and Structures IS 4091-1979 Code of Practice for Design and Construction of Transmission Lines and Poles Chetan, 2007, Civil Construction Issues, Proceedings of workshop conducted for M/s GTL Infra Ltd., Indian Institute of Techology Madras, Chennai, Nov 3rd 2007

Gandhi S R, 2007, Geotechnical Issues related to Telecommunication Tower Construction, Proceedings of workshop conducted for M/s GTL Infra Ltd., Indian Institute of Techology Madras, Chennai, Nov 3rd 2007

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Gettu R, 2007, Concrete Properties, Proceedings of workshop conducted for M/s GTL Infra Ltd., Indian Institute of Techology Madras, Chennai, Nov 2nd 2007 Kalyanraman, 2007, A Review of Steel Tower Skeleton System, Proceedings of workshop conducted for M/s GTL Infra Ltd., Indian Institute of Techology Madras, Chennai, Nov 3rd 2007 Menon, 2007, Fixing of Ground Based and Roof Top Towers-Structural Issues, Proceedings of workshop conducted for M/s GTL Infra Ltd., Indian Institute of Techology Madras, Chennai, Nov 2nd 2007 Advantages and disadvantages of tubular and angular towers, http://www.monsterfm.com/tech/tower/towerspecs.htm#top (accessed April 2009) Estimate of Cell sites construction 2007, http://www.airtel.in/wps/wcm/connect/ (accessed January 2009) Indian Telecom Sector Analysis (2006-2007), http://www.rncos.com/Report/IM073.htm (accessed November 2008) ITU World Telecommunication base indicator 2007, www.itu.int (accessed October,2008) Site Installation, http://www.topcomco.com/civil_work.htm (accessed March 2009) Site Survey, http://www.topcomco.com/site_survey.htm (accessed January 2009) Structural changes in the Indian Steel Industry 2003, http://jpcindiansteel.nic.in/structure.asp (accessed December 2008) Tower design specifications, http://www.rajessh.com/towerdesignspecifications (accessed February 2009) Tower materials, http://www.topcomco.com/ti.htm (accessed April 2009) Tower specifications, http://www.monsterfm.com/tech/tower/towerspecs.htm (accessed January 2009) Why cell tower business is booming?, www.financialexpress.com/news/whys-cell-tower-business-booming/407427/ (accessed April 2009)

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THANK YOU
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